Arun Kumar Gupta

Introduction: Definition of safety, Hazards in common chemical industries, Need and

significance of safety in chemical industries, Important case histories.

Hazards associated with chemical substances: Safety related properties of hazardous

substances, Classification of dangerous substances, Hazards of flammable and

explosive materials, Hazards of common unit operations, Hazards of common chemical

reactions, Safety in bulk storage of hazardous chemicals, Safety in shelf storage of

hazardous chemicals, Corrosion in chemical industries.

Hazards associated with chemical plants: Safety in use of pipelines and their fixtures

in industries, Safety in use of cross country pipelines, Safety in process control systems

and use of instruments, Safety in pressure system design and operation, Safety in

process plant maintenance, Safety considerations in plant site selection and layout

planning.

Hazard identification and assessment: Hazard identification techniques, Hazard and

operability studies (HAZOP), Fire and explosion index and toxicity index, Fault tree and

event tree analysis, Emission of toxic and flammable gases and vapours, Dispersion of

toxic and flammable gases and vapours, Heat radiation from vapour cloud explosions, jet

fires, fire balls and pool fires, Probability of accidents and risk calculation.

Safety management: On site emergency planning, Off site emergency planning,

Personnel protection and other safety devices, Safety in chemical laboratories, Reliability

engineering.

D A Crowl, J F Louvar, Chemical Process Safety Fundamentals With

Applications, Third edition, Prentice Hall, Boston (2011).

E Sanders, Chemical Process Safety Learning From Case Histories, Third

edition, Elsevier, Oxford (2005).

R R Tatiya, Elements of Industrial Hazards, CRC Press, London (2011).

B O Alli, Fundamental Principles of Occupational Health and Safety,

Second edition, International Labour Office, Geneva (2008).

V Marshall, S Ruhemann, Fundamentals of Process Safety, Institution of

Chemical Engineers, Warwickshire (2001).

S Mannan (Editor), Lees’ Process Safety Essentials: Hazard Identification,

Assessment and Control, First edition, Butterworth-Heinemann, Oxford

(2014).

Lees, F. P., “Loss Prevention in Process Industries 3 volume set”

Butterwort - Heinemann, Oxford (1996).

Attendance: 5

2 Quizs: 15

Mid Sem: 30

End Sem : 50

Assignment: 5 marks each

In the chemical, petrochemical and most other industries,

occupational safety program,

Focus on

Personal safety

It can apply to workers in a manufacturing plant, a

research laboratory or pilot plant, and even to office locations

• Prevent harm to

workers from workplace accidents such as falls, cuts,

sprains and strains, being struck by objects, repetitive motion

injuries, and so on.

Process Safety is defined as

“a discipline that focuses on the prevention of fires,

explosions, and accidental chemical releases at

chemical process facilities”.

Another definition is that process safety :

prevention of, preparedness for, mitigation of,

response to, or restoration from catastrophic

releases of chemicals or energy from a process

associated with a facility.

Brief history of process safety

Concepts of management systems

Risk based process safety proposed by the

Center for Chemical Process Safety (CCPS) in 2007

The Center for Chemical Process Safety (CCPS) was

created by the AIChE in 1985 after the chemical disasters

in Mexico City, Mexico, and Bhopal, India.

Product of CCPS activities:

has been a series of guidelines to assist those implementing various elements of a process safety and risk management system.

CCPS created Safety and Chemical Engineering Education (SACHE) committee

which develops training modules for process safety.